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Mag/@440 Patented Dec. 3, 1953 3,112,552 NEEDLED FABRIC STRUCTURE Alexander M. Srni ii iii, Elhin, N.C., assignor to Chatham Manufacturing Company, Elkin, N.C., a corporation of North Qarolina Filed July 3, 1962, Ser. No. 207,303 12 Claims. (Cl. 161-69) The present invention relates to a new and improved needled fabric structure formed from a web or batt of loosely matted fibers which may be either synthetic or natural.

This application is a continuation-in-part of my prior copending United States application serially numbered 29,115, filed May 13, 1960, now United States Patent No. 3,090,099 and entitled Method of Needle Punching Fabrics so as To Interlace the Fibers Thereof and my prior copending United States application, serially numbered 31,910, filed May 26, 1960, now United States Patent No. 3,090,100 and entitled Method of Needle Punching Fibers To Make Needled Fabrics or the Like. Each of the aforementioned copending applications disclose the new and improved fabric structure of the present invention as Well as claiming methods and apparatus for producing the new and improved fabric structure claimed herein.

Needled fabric structures, which are oftentimes referred to as non-woven fabric structures although all nonwoven fabric structures are not necessarily needled, are made on needle looms and derive coherence and strength from interfiber entanglement and accompanying frictional forces. Heretofore, non-woven fabrics such as felts and the like have been produced from Wool and wool-like fibers by various mechanical working processes involving rufiing, squeezing and rolling under appropriate conditions of humidity and temperature. Needle looms have been employed for punching the non-felting natural and synthetic fibers in loosely matted batts in an effort to obtain coherence from interfiber entanglement. While such prior needled fabric structures had some coherence, their strength characteristics and durability have not been good enough to justify commercial production for end products such as blankets, wearing apparel, draperies, or the like wherein the end products were subjected to considerable strains from use, laundering, dry cleaning or the like.

Prior art needled fabric structures were usually made by subjecting first one side of a web or batt of loosely matted fibers to needling from a needle board having an array of needles and then subsequently subjecting the other side of the web or batt to needling, the web or batt being run through the needle loom a number of times in order to reorient the fibers and obtain as much coherence as possible from such reorientation. In some instances, the webs or batts were simultaneously needled from both sides, the web or batt being passed through the needle loom a number of times. While such prior art needling of a web of loosely matted fibers resulted in some interlocking of the fibers due to reorientation of fibers, the resulting fabric structure lacked sufficient coherence to allow finishing operations such as raising fibers by napping and were characterized by excessive shedding of surface fibers, as Well as a difference in fiber tie-in on one side as compared with that of the other side. Also, such prior needled fabrics elongated or stretched both in a widthwise and lengthwise direction under normal use because of the lack of proper and positive interlocking of fibers throughout the structure.

The present invention contemplates producing a needled fabric structure having a uniform and positive interfiber entanglement throughout as opposed to random entanglement. By needling the web or batt of loosely matted fibers so that the fibers have a chain entanglement throughout the fabric structure both in the interlacing and interlooping of fibers, the fabric structure of the present invention has the necessary coherence, strength and density to make it capable of comparison with woven fabrics having similar weight and thickness characteristics. The needledfabric structure of the present invention by having chain entanglement of fibers throughout, as will be defined in more detail later in the specification, may be napped on both sides, the napping resulting in uniform appearance on both sides. After napping, the fabric structure has better tensile strength and separation strength (fiber tie in strength i.e., strength determined in a direction perpendicular to the plane of the fabric) than heretofore realized. In addition, the needled fabric of the present invention has a better hand than non-woven needled or bonded fabrics heretofore produced and also requires fewer passes through the worker rolls of a napper to raise fibers for a soft surface.

Throughout the specification wherever the term interlooping is used, it defines a subsurface binding together of fibers in a web or the like of loosely matted fibers, the bonding being accomplished by passing fibers through the loops of other fibers previously oriented below the surface of the Web. Interlooping of fibers is akin to knitting as it provides entanglement of fibers by loop engagement rather than a binding by a tying action. On the other hand, the term interlacing as used throughout the specification is intended to define a binding together of fibers primarily from one outside surface of a web to the other outside surface of a web. interlacing of fibers is somewhat similar to a sewing action although it does not depend on a continuous threaded action. In interlacing, the ends of fibers lying on one surface are carried through the web body and then returned to the initial side by another path so as to become oriented in a manner analogous to a thread in sewing as distinguished from interlooping where the binding is confined to subsurface fibers. The term chain entanglement referred to herein is generic to intermingling, interlooping and/or interlacing of fibers where coherence results from continuous entanglement of fibers oriented along a plane lengthwise of the fabric structure.

An important object of the present invention is to provide an improved needled fabric structure deriving its coherence and strength from fibers uniformly interlocked throughout by chain entanglement of fibers, the fabric structure having greater tensile and separation strength, and density than heretofore obtained.

Ancillary to the preceding object, it is a further object of the present invention to produce a needled fabric structure capable of napping on both sides without materially affecting its tensile strength either Warpwise or fillingwise, the fabric structure after napping having a uniform appearance on both sides.

Another object of the present invention is to produce a needled fabric structure having fibers therein reoriented into a definite interlooping and/ or interlacing pattern of chain entanglement.

Still another object of the present invention is to provide a needled fabric structure capable of napping on both sides and having a minimum amount of shedding after napping, the fibers of one side being tied-in equally as well as the fibers of the other side.

Still another object of the present invention is to provide a needled fabric structure having a lower thermal transmission characteristic than a woven fabric of similar weight and thickness.

A further object of the present invention is to provide a needled fabric structure having an interfiber entangle- 3 ment which is uniformly developed from both sides as the web of loosely-matted fibers is needled.

Ancillary to the preceding object, it is a further object of the present invention to provide a new and improved needled fabric structure produced by small increments of advancement of a web of loosely-matted fibers between successive penetrations of patterns of needles so that some of the fibers oriented on one penetration are re-oniented on the next successive penetration.

These and other objects and advantages of the present invention will appear more fully in the following specification, claims and drawings in which:

FIGURE 1 is a side elevational view of an improved apparatus for producing the non-Woven fabric material of the present invention by an improved novel method;

FIGURE 2 is an end elevation looking from the right of FIGURE 1, parts being omitted for the purpose of clarity;

FIGURE 3 is an enlarged vertical sectional view, partly in elevation, and taken on the line 33 of FIGURE 2;

FIGURE 4- is an enlarged fragmentary view of a web guide plate taken on the line 4-4 of FIGURE 3;

FIGURE 5 is a view taken on the line 5-5 of FIG- URE 4;

FIGURES 6 and 7 illustrate progressive steps of interloping fibers in chain entanglement as the web of material passes through the apparatus from the left to the right, the figures showing an opposed pair of cooperating upper and lower needles;

FIGURE 8 is a schematic view showing the paths of the pair of cooperating needles in FIGURES 6 and 7 superposed upon one another;

FIGURES 9 through 11 schematically show the pene tration pattern of a pair of opposed needles through a web moving from the left to the right in intermittent step-by-step increments;

FIGURES 12, 13 and 14 schematically show the interlooping of fibers as provided by the movement of the needles shown in FIGURES 9 to '11, respectively;

FIGURE 15 is a fragmentary exploded schematic view illustrating contiguous lengthwise or warpwise extending rows of fibers in chain entanglement, it being understood there is also interlocking of fibers between rows due to the close proximity of the rows;

FIGURE 16 is a fragmentary plan view of the fabric structure of the present invention illustrating the same after needling and prior to napping, the rows being faintly visible;

FIGURES 17, 17a, and 17b illustrate stress-strain curves in a warp-wise or lengthwise direction, comparing woven fabric structure, a needled fabric structure of the prior art and a needled fabric structure of applicants invention, respectively;

FIGURES 18, 18a and 18b illustrate stress-strain curves in a filling-wise or widthwise direction, comparing woven fabric structure, a needled fabric structure of the prior art and a needled fabric structure of applicants invention, respectively;

FIGURE 19 is a side elevational view of a modified form of apparatus for producing the novel fabric structure of the present invention by a slightly modified method;

FIGURE 20 is an end elevational view looking from the right of FIGURE 19;

FIGURE 21 is an enlarged vertical sectional view partly in elevation and taken on the line 21-21 of FIGURE 20;

FIGURES 22 and 23 illustrate progressive steps of interlacing fibers in a chain entanglement of fibers as the web passes through the apparatus of FIGURES 19 to 21;

FIGURE 24 is a view illustrating interlacing combined with interlooping within the interior of the web, the view showing, for purposes of illustration only, needles penetrating from opposite sides of the web at the same time, it being understood the needles alternately penetrate the web and travel in similar paths; and

FIGURE 25 is a schematic view of the needle path through the Web resulting from the coordination between needle movement and advancement of the material of the apparatus of FIGURES 19 to 21, which produces the novel fabric structure of the present invention.

The needled fabric structure of the present invention may be best understood from a description of the method of making the same and the apparatus for accomplishing such method.

Referring now to the drawings wherein like character and reference numerals represent like or similar parts and in particular to FIGURE 1, a web or batt of loosely matted fibers generally designated at 10 is illustrated moving from the left to the right of the figure through a needle punch machine generally designated at 12. Passing from the machine 12 at the right hand side of the figure is the non-woven fabric material of the present invention shown in broken lines and generally designated by the numeral 14. The web or batt of fibrous material may be continuously fed from a conventional carding machine or other web forming machine where the fibers are loosely formed into web It} or it may be supplied from rolls of such material after the material has been taken from such machine and formed into the roll. In some cases, it is desirable that the fibers of the web 10 are cross-laid as there is a certain amount of inherent entanglement of the fibers in this direction and thus when the web is needled, it assists in giving the web tensile strength in a widthwise or fillingwise direction. In order that the fibers may be cross-laid, conventional cross-lappers may be used between web formers and the machine 12.

If desirable and depending on the type of end product to be made from the needled fabric structure, the web 10 in FIGURE 1 may be formed from two or more layers of loosely matted fibers such as 16 and 18 (FIGURE 6). Oftentimes, it is desirable to separate the layers by a loosely woven scrim 20 or by warp threads or yarn.

After the non-woven fabric structure 14 is produced by the apparatus 12, it will be understood that subsequent treatment of the fabric may occur. In instances where the needled fabric structure 14 is to be used for blankets or the like, each of the surfaces of the needled fabric structure can be napped by conventional napping processes. Where the needled fabric structure is to be used for wearing apparel, draperies or the like, it may be brushed and in other instances may be dyed or chemically treated without materially affecting its strength. By the unique chain entanglement of interlooping and interlacing fibers accomplished by the present method and apparatus the produced needled fabric structure of the present invention 14 has a high pull apart or separation strength and it retains a majority of this separation strength even after napping.

While the present invention primarily results in interlooping fibers, it also results in some interlacing of fibers. By suitable changes in the method and adjustments in the operation of the machine, more or less interlacing of fibers can be obtained. In any event, the present invention contemplates a fabric structure wherein there is chain entanglement or interlocking of fibers uniformly and continuously throughout the same regardless of the amount of interlooping and interlacing.

In order to produce the novel fabric structure of the present invention having a chain entanglement of interlooping of fibers in the web 10 as well as some interlacing in fibers, the web is advanced through the machine in intermittent step-by-step motion between opposed pat terns of needles 22 and 24. The needle patterns 22 and 24 are each arranged to move on a path of penetration at an acute angle to and in a direction opposite to the. direction of travel of the web It). While the needle patterns 22 and 24 swing in an are as will be explained in more detail later in the specification, the radius of the arc is sufiiciently great that the needles for all practical purposes travel substantially in a straight line when penetrating into or withdrawing from the web. In the preferred form of the invention, the center rows of needles of each pattern are made tangent to their are when the needles are in a position of complete penetration within the web 1%. When arranged in this manner, the needles travel in a path at an acute angle to the web travel and their path of travel is substantially parallel to the iongitudinal axes of the needle shafts. An alternative arrangement is to position the center row of needles of the patterns 22 and 24 at a slight angle to the tangent of their arc when the needles are in a position of complete penetration in the web 1%. When arranged in this latter manner, the path of travel of the needles is at an acute angle to web travel but such a path is also at a slight angle to the longitudinal axes of the needles.

While the needle patterns 22, and 24 are shown penetrating at an acute angle to and in a direction opposite to the direction of web travel for purposes of description, it will be understood that the path of travel of the needles could be at an acute angle to and in the same direction as the direction of web travel.

Needle patterns 22 and 24 include needle boards 26 and 28 respectively. An array of needles 36* is carried by the needle board 26 whereas another array of needles 32 which oppose the needles so is carried by the needle board Needles 3i are arranged on needle board 26 in a pattern which is a mirror image of the pattern of needles 32 arranged on the needle board 23. As heretofore mentioned, the needles so and 32 enter the web at an acute angle to the direction of feed of the web and since the two needle patterns 22 and 24 are mirror images of one another and operate in cooperation with one another, the paths of a pair of needles 3t? and 32 will cross in a median plane of the web lit. A schematic representation of the paths of needles 3i) and 32 is shown in FIG- URE 8 and while the paths are shown as crossing, it will be understood that the paths are superposed one upon the other as an opposed pair of needles never enter the web simultaneously and further the web moves in between successive penetrations of opposed needles.

A confined throat 34 defined by a pair of spaced apart web guide plates 36 and 38 provide a path for the web It to travel as the needle patterns 22 and 24 alternately punch or needle opposite surfaces of the web, the web being moved a small increment in between successive penetrations of the patterns. Guide plates 36 and 38 are provided with curved inlet portions 40 and 42 which define a gradually decreasing infeed portion 44 for the throat 34. The infeed portion 44 guides the web 16 as it is compressed to a desired thickness as defined by the dis tance between the two guide plates 36 and 38.

Each of the guide plates 36 and 33 is provided with a plurality of holes 46, the holes 46 being arranged to re eeive the needles 3G and 32 of patterns 22 and 24 respectively. As shown in FIGURES 6 and 7, the needles which enter the web at an angle thereto pass through a pair of holes or slots 45 in the plates 36 and 3%, respectively. The holes or slots 46 are elongated in the direction of travel of the web. The array of needles 3% and 32 are substantially identical in construction and include barbs 48 arranged along the surfaces of the same, the barbs being adapted to engage and orient fibers of the web It as the needles are moving on their penetrating stroke, but not engaging the fibers on the withdrawal stroke.

Referring now to FIGURES 6 through 8, inclusive, as well as to the schematic FIGURES 9 through 14, inclusive, the letter T represents the direction of travel of the web it) through the confined throat 34. As mentioned above, the motion of the Web through the throat is in step-by-step increments with penetration of the web by the patterns of needles 22 and 24 occurring when the web is stationary. In FIGURE 6, the needle 3d of the upper pattern of needles 22 is shown penetrating the web and carrying with it subsurface fibers as well as some surface fibers of the same. FIGURE 6 illustrates the orienting of fibers from the upper surface of the web to a position wherein some of the looped ends of the fibers are positioned immediately below the surface opposite the surface of penetration. A certain amount of the fibers being oriented will pass through and out of the surface of penetration. FIGURE 12 schematically shows the loops of fibers oriented by the penetration of the needle 39' in FIGURE 6. In FIGURE 7, the needle 32 which is the mirror image of needle 30 is shown penetrating the web from beneath and carrying with it some surface fibers and some subsurface fibers of the lower surface of the web. It will be understood that prior to the penetration by the needle 32, needle 30 will have been completely withdrawn from the web and the web will have been moved in the direction of the arrow T to a small increment.

When the needle 32 enters the web as shown in FIG- URE 7, its point of penetration is such that fibers picked up on the surface of the web as well as subsurface fibers are carried through the loops and entangled with fibers previously oriented by the needle 30. This is shown schematically in FIGURE 13 wherein the fibers are passing upwardly to the left of the figure, through the subsurface loops of the fibers previously oriented by the needle Silt. Also as shown in FIGURE 13, loops of the fibers oriented by the needle 32 are positioned immediately beneath the surface of the web opposite the surface of penetration by the needle 32. After needle 3-2 is withdrawn from the web, the web It is again advanced a small increment. Needle 30 begins its penetration after the web has stopped and as shown in FIGURE 14, fibers being oriented by the needle 30 are threaded through loops and mingled with fibers previously oriented by the needle 32. The alternate penetration of the oppositely disposed needles 30 and 32 continues as the web is moved in stepby-step motion through the confined throat 34 resulting in a locked chain-like path of oriented fibers.

FIGURE 8 illustrates the paths of penetration of opposed mirror image needles 30 and 32 superposed upon one another. Each pair of opposed needles Fall and 32 is arranged to penetrate through the web and intersect in a median plane represented by the broken line M of the Web It). It will be understood that the web 10 moves a small increment between successive penetrations of a pair of opposed needles 3t} and 32, the increment being such that the initial penetration of the needles will be forward of the position where the opposed needle extended out of the web so that loops previously oriented by the other needle may be engaged. A schematic illustration of the movement of the needles through the median plane M relative to the movement of the web is shown in FIG- URES 9 to 11 inclusive. In FIGURE 9, the stationary web is penetrated by the needle 30, the needle passing through the median plane of the web at a point designated A. As shown in FIGURE 10, the needle 36 has been withdrawn from the web, the web has been advanced a small increment and then the needle 32 has penetrated the web. In the positions shown, the needle 32 intersects the median plane M of the web at B and the distance between A and B represents the increment of advancement. FIG- URE 11 is a further sequential operation showing the needle 32 having been withdrawn, the web advanced and then the needle 39 again penetrating the web and intersecting the median plane at C. FIGURES 12, 13 land 14 show the sequence of interlooping and engagement of fibers to cause a chain entanglement of fibers in a row as represented by the movement of needles as shown in FIGURES 9 to 11, respectively.

While FIGURES 12 to 14 do not show surface fibers passing completely through the web, it will be understood that some fibers will be carried through the web and there will be some interlacing of fibers in the chain entanglement of fibers so as to have a surface-to-surface binding of the web as well as a subsurface-tosubsurface binding of the web by interlooping.

Referring now to FIGURE 4, the needle pattern 22 of needles 3% is illustrated, it being understood that the pattern 24 of needles 32 is a substantially mirror image of the pattern 22. Needles 36 are arranged in a plurality of rows extending transverse of the direction of travel of web 18. The rows of needles are staggered so that more needles may be punching the web transversely of the same in each widthwise inch. In other words, because the size of the needles will not permit the needles to be placed in close enough spaced relationship widthwise of the web, the rows of needles are staggered so as to provide a high number of needles punching the web for each widthwise inch of the web.

To accomplish effective interlooping by the above described method, it has been found that each needle pattern 22 and 24 must have an array of needles which will provide a range of needle punches per widthwise inch of the web of about 25 punches to about 75 punches. Thus, in effect, there will be 25 to 75 paths of punches as the web is advancing between the needle patterns 22 and 24. With the above range of widthwise punches, it has been found that each needle of each pair of opposed needles should penetrate the web 10 in a range of 6 to penetrations per linear inch of the web to obtain effective interlooping of fibers. On the other hand, effective interlacing as well as inter-looping of fibers can be obtained within a range of 4 to 20 penetrations per linear inch. A preferable range of punches per linear inch is 7 to 14 penetrations for each needle of each pair of needles. The number of penetrations per linear inch is accomplished by moving the web in step-by-step increments for each successive penetration of a needle pattern, the increment of movement being determined by the range desired.

Barbed penetration, which is the distance of penetration through the web of the barb closest to the point of the needle, has been accomplished in a range of from the surface of the web opposite the surface of penetration to a point Where the aforesaid barb extends one-half of an inch from the surface. A range of barbed penetrations for maximum interlooping plus some interlacing is obtained in a range from the surface of the web to one-eighth of an inch beyond the surface whereas a range of barbed penetrations for maximum interlacing and good interlooping has been found to be one-eighth of an inch through the web and no greater than onehalf of an inch through the web.

As mentioned above, the path of penetration of the needles is at an acute angle to the direction of travel of the web 19. The range in angularity of the path of penetration with respect to a normal through the web has been found to be about 8 to about 30 with an angle of the order of 20 preferable. This range of angularity is effective both when the longitudinal axis of the shaft of the needle is parallel to the path of penetration and when the axis of the shaft of the needle is at a slight angle to the path of penetration.

As is now apparent, the arrangement of needles traveling at an acute angle to the path of the web provides a needled fabric having good tensile and separation strength as well as good compactness and density. Because the nonwoven fabric produced by the aforesaid method results in interlooping as well as some interlacing chain entanglement throughout the length of the Web, the fabric may be subjected to subsequent operations on both sides such as napping with uniform results. The interlooping of fibers causing a subsurface-to-subsurface binding permits the non-woven fabric to be napped without materially reducing its tensile strength or its separation strength. It has been found that by utilizing the aforesaid method, a non-woven fabric capable of use in making blankets, outerwear fabrics and the like can be made by punching the fabric at least 600 punches per square inch upon one pass through the opposed patterns of needles. More passes through opposed pairs of needled boards and more punches per square inch may be employed in certain specific instances if desired, however, for emphasis it should be pointed out that the fabric of the present invention derives its uniqueness from sequence in which the punches are made and the manner in which the entanglement is developed rather than from any number of punches per given area.

The chain entanglement of the foregoing method is achieved only when fibers oriented by a given needle penetration are further oriented themselves or are entangled with other fibers under the influence of the second cooperating needle of a pair and the process repeated continuously. It can be readily seen that there is a definite limit to the distance which the fabric can be advanced between successive needle penetrations and still have the fibers arranged by one needle entangled or reacted on by the cooperating second needle on the other side of the fabric. This allowable fabric advance increases with increased angle of the path of the needle penetration and with the thickness of the fabric being needled. Usually the fabric advance between successive punches is limited by practical considerations to less than 40% of the needled fabric thickness. Of course, the fabric advance (reciprocal of punches per lineal inch) may be varied in the range below the limiting value required for continuous or chain entanglement, and such variation affects the character of the entanglement, that is, interlooping or interlacing or knot formation. The degreee of barb penetration also affects the character of the entanglement; it being understood that all of the aforementioned variables are closely interrelated. Generally, more interlooping of fibers occurs when the nonwoven fabric produced is one-eighth inch or greater in thickness. Likewise, the more punches per linear inch produces more interlooping whereas the lower end of the range produces more interlacing. Further, more interlooping of fibers occurs at the lower end of the barb penetration range whereas interlacing increases with increased barbed penetration.

Referring back to FIGURES 1, 2 and 3, the improved needle punching apparatus 12 for accomplishing the above-described method is best illustrated. The needle punching apparatus 12 includes a frame structure 48 made from suitable vertical standards 50, side frame members 52 and cross members 54. Mounted on the upper side frame members 52, on each side of the frame structure 48 are a pair of spaced parallel vertically extending plates 56 which are adapted to support there-between the guide plates 36 and 38. The guide plates 36 and 38 are adjustably supported in any suitable rnanner to the side plates 56. These plates may be adjusted relative to each other so that the spacing between the plates may be varied to conform to the desired compression of the web 10. Side plates 56 are provided with horizontally extending slots 58 and 60. Aligned slots 58 of side plates 56 are adapted to receive the ends of a shaft 62 which supports one pulley 64 of an endless conveyor structure 66. The end portion of shaft 62 which extends outwardly of the plate 56 as shown in FIGURE 1, is provided with a drive sprocket 68.

Slots 60 in plates 56 receive the ends of a shaft 70 which supports an outfeed roller 72. Carried outwardly of the plates 56 on the end of the shaft 70 is a drive sprocket 74 (FIGURE 1). A one-way clutch and brake assembly (not shown) is coupled to the other end of shaft 70. A drive chain 76 trained around the sprockets 68, 74 and an idler sprocket '78 causes the pulley 64 to be rotated in step-'by-step increments when the shaft 70 is rotated in step by-step increments by the one-way clutch and brake assembly (not shown).

Cooperating with the outfeed roller 72 is a Weighted roller 8% carried on a shaft 82 supported in diametrically opposed slots '84. Weights may be provided on the outer ends of the shaft 82 so that the roller 80 bears against the upper surface of the non-woven fabric 14 as it is discharged from the machine.

A crank arm 86 connected to the drive member of the one-way clutch and brake assembly (not shown) is actuated by a connecting arm 88 pivotally connected thereto and to a disk or wheel 39 (FIGURE 2) keyed to a shaft 9%) rotatably supported in the bearing pillow blocks 92. Shaft 93 also carries a drive wheel 94 which is rotated by a belt 96 coupled to a source of power such as the electric motor 98. As will now be understood, continuous rotation of the shaft 91 by the motor 98 will cause the crank 85 to oscillate back and forth. Since the crank is connected to the drive member of the one-way clutch and brake assembly, clockwise movement of the crank will cause rotation of the outfeed roller 72 in a clockwise direction as well as rotation of the pulley 64 and movement of the conveyor structure 66 in a direction of web feed. During counterclockwise movement of the crank 85, the roller 72 and the conveyor structure 66 will be stationary and, consequently, there will be no feed of the web through and out of the machine.

As previously stated, the upper needle pattern 22 includes a plurality of downwardly extending needles carried in the needle board 26. Likewise, the lower needle pattern 24 includes a plurality of upwardly extending needles 32 carried in a lower needle board 28. Needle board 26 is fixedly mounted on the end of elongated rocker arms 1% which are pivotally supported as indicated at 1%2 to a pair of vertical standards 104 fixedly secured on opposite side frame members 52 of the frame structure 4-3. Lower needle board 28 is fixedly supported as indicated at 166 to the ends of elongated rocker arms 108 also pivotally supported as indicated at 110 to the vertical standards 104.

Connecting rods 112 on opposite sides of the needle boards, pivotally connect the upper needle board 26 to the lower needle board 28 as indicated at 114. Thus, when the lower needle board is moved vertically upwardly and downwardly, the upper needle board 26 is simultaneously moved upwardly and downwardly.

Extending vertically downwardly beneath the lower needle board 23 and fixedly connected thereto is a pair of brackets 116 to which the forward ends of the rocker arms 1&8 are connected. The brackets 116 are pivotally connected as indicated at 1 18 to a pair of crank arms 126' coupled to cranks 122 carried on a shaft 124 supported in bearing pillow blocks 126. The shaft 124, Which rotates the cranks 122, is provided with a drive sprocket 128 driven by a chain 130 trained about a sprocket 132 keyed to the drive shaft 90.

As is now apparent from the foregoing description and the drawings, the feed of the web 1t in step-'by-step increments is timed to the movement of the needle patterns 22 and 24. Drive shaft 9i? is rotated by motor 98 and its rotation causes continuous up and down movement of the patterns 22 and 24 about their pivotal axes MP2 and 110, respectively. Timed to the up and down movement of the patterns 22 and 24 is the step-by-step feeding of the web it} between the patterns. This is also accomplished by rotation of the shaft 9%) which in turn oscillates the crank arm 36 of the one-way clutch and brake assembly causing step-by-step feeding of the web in timed relationship to movement of needle patterns 22 and 24. In more detail and assuming the upper patterns of needles 22 is on its down stroke, the web 1% will be stationary as the crank arm 86 is moving in counterclockwise direction. After the array of needles 3% of pattern 22 have penetrated the Web orienting the fibers as heretofore described, the array of needles 3h will begin to withdraw from the web. When the needles 3! are completely out of the web and prior to the array of needles 32 of pattern 24 entering in the web, the crank arm 86 will rotate in a clockwise direction to advance the web the desired increment in its step-by-step movement. Immediately after the web has stopped, the lower pattern of needles 24 will begin their penetration through the web.

Referring now to FIGURE 3, it will be noted that the first few rows of needles 3t) and 3 2 of upper and lower needle patterns 22 and 24 respectively pass through the curved inlet portions 40 and 42 of guide plates 36 and 38. Some of these needles do not pass completely through the web as heretofore described but merely enter the Web and compress the web in the tapering infeed portion 44 of the throat 34. In other words, the needles in the forward portion of the patterns are not entirely efiective to cause interlooping and/or interlacing of the loosely matted fibers but they do compress the web to proper thickness and density for passage through the confined throat 34. The contour of the plates 36 and 38 is such that they conform to the Web as it is compressed, that is, they are spaced apart a distance which allows no up and down flapping motion of the web during the needle process.

Referring to FIGURE 15, the fabric structure 14 of the present invention is schematically illustrated in an exploded view with adjacent needled rows of fibers separately shown. Because of the needled pattern illustrated in FIGURE 4, each pair of cooperating needles 30 and 32 of the upper and lower needle boards 26 and 28 respectively operate to make a chain entanglement of fibers in the fabric structure lengthwise or warpwise of the same but with the interlace and interloop of one row being offset longitudinally with respect to an adjacent contiguous row. For example, in FIGURE 15, the chain entanglement of interlaced and interlooped fibers of one row schematically represented at R is offset from the next row schematically represented at R and so forth throughout the width of the fabric. The broken line L is for reference only and illustrates an imaginary line extending across the width or in a fil-lingwise direction of the fabric structure. From this imaginary line L, it will be noted that the fibers oriented in the row R are staggered longitudinally from those oriented in the row R and those in R are staggered from those in R" and so forth throughout the width of the fabric structure. Since the rows across the width of the fabric structure are substantially contiguous and formed by the pairs of cooperating needles as heretofore described, it will now be understood that one pair of cooperating needles will act on some fibers in adjacent rows so as to firmly lock the fabric structure together in a widthwise or fillingwise direction. In addition, strength in a widthwise or fillingwise direction may be supplemented by providing the fibers in the batt to crosswise of the batt prior to needling since the fibers when laid crosswise of the batt have some coherence from interfiber entanglement and accompanying frictional forces. The subsequent needling as heretofore described will further increase the widthwise or fillingwise strength of the fabric structure along with the lengthwise or Warpwise strength of the structure.

FIGURE 16 is a fragmentary plan view of the fabric structure of the present invention on an enlarged scale and prior to napping. In FIGURE 16, it will be noted that the rows R, etc, are faintly visible to the naked eye. The appearance on both the upper surface of the fabric structure and the lower surface is identical. However, after the fabric structure has been napped or brushed, as determined by the end product for which the fabric structure is to be used, the rows are completely invisible and the surfacesof the fabric structure are identical in appearance and hand. The fabric structure of the present invention after use, laundering, and dry cleaning still maintains its uniformity in appearance on both sides as well as maintaining its strength characteristics.

A batt containing percent Acrilan fibers was made into a needled fabric structure according to the present invention andwascompared'to (1) awoven fabric structure of. substantially the same weight and thickness after 11 napping made from 100 percent Acrilan and (2) a needled fabric structure of the prior art made from 100 percent Acri-lan fibers. The needle'd fabric structure of the present invention was passed through the needle loom once whereas the need-led fabric structure of the prior art was passed through the needle loom six times, it being needled first on one side and then the other side until each side had been needled three times. The total number of needle penetrations per square inch of the fabric structure of the present invention was substantially the same as that of the prior art after six passes through a needle loom. The results of the comparative tests are shown in the following table and in the stressstrain curves of FIGURES 17, 17a, 17b, 18, 18a and 18b. The stress-strain curves of FIGURES 17, 17a, 17b, 18, 18a and 1812 were compiled from tests conducted on a Thwing-Albert Strength Tester utilizing one-inch strip samples. The pulling force was recorded as the jaws initially spaced at three inches, separated at a rate of speed of twelve inches per minute.

TABLE I Comparison 100% Acrzlan Blankets After Napping Needied Necdled Woven (Prior art) (Applicant.)

Fillingwise 0r widthwise Breaking Strength-1bs. (1 inch strip) 18 ll 42 Warpwise or lengthwise Breaking Strengthlbs. (1 inch strip) 40 12 31 Weight ounces/sq. yd 8.7 8.7 8. 7 Thickness, inches measured 0.01 lbs,

sq. in. pressure S4 .30 32 Stiffness, mg. cm 300 1200 1200 compressibility, percent 60% 36% 35% Thermal Transmission, Btu/Hr /sq.

ft 95 80 75 Approx. No. Passes over Wor to Raise Nap 300 70 30 Shedding, gins/sq. It;

1st Side 0.36 0.57 0. 32 2nd Side 0.30 0.32 0. 29

From the above table and from the stressstrain curves, the comparative tests illustrate that the needled fabric structure of the present invention has better strength than the prior art needled blanket in both the widthwise and the lengthwise direction; this demonstrates the superior fiber tie-together of chain entanglement. The widthwise or filling strength of woven blankets is usually weak since the filling yarns are degraded in the process of raising fibers from them to form the blanket nap. By comparison the blanket of the present invention has a higher and more equally balanced strength. The fabric structure of the present invention is superior to the woven and prior art fabric structure in thermal transmission. Note the unevenness of shedding in the case of the prior art needled fabric structure which reflects a diiference in fiber tie-in strength of one side with respect to the other side. It should be further noted the loss of strength resulting from napping is much less in the fabric structure of the present invention as compared to that of prior art and the fillingwise strength of the woven structure. An important consideration in the above test will be noted in the number of times each of the specimens were passed over the worker rolls to raise substantially the same nap. In the present invention, it required only thirty passes over the worker roll Whereas in the pror art needled fabric structure 70 passes were required and in the woven fabric structure 300 passes were required.

The fabric structure of the present invention may be made by a slightly modified method and apparatus as disclosed in FIGURES 19 through 25, inclusive. In more detail, and referring first to FIGURES 22 through 25 inclusive, the web moves through the throat 30 be tween the guide plates 32 and 34' in the direction of the arrow A in step-by-step motion. The step-by-step motion of the web It) is coordinated with the movement of the web on the previous penetration stroke.

needles 26' and 28 so that either set of the needles initially penetrates the surface of the web when the web is making its step motion. This causes the fibers adjacent the surfaces of the web to be caught by the needle points and moved in a substantially horizontal direction for a short distance. Then the web stops and the needles of the particular pattern 22 or 24' which is penetrating, continue the perpendicular movement through the web, the barbs 42' of needles carrying with them some of the fibers near the surface of the web which have been oriented horizontally as well as other unoriented fibers picked up near the surface during the course of needle movement through the web. When the needles of a particular pattern 22' or 24- such as the needles 26 as shown in FIGURE 22 have passed completely through the web with their lowermost barb 42' positioned adjacent a surface of the web or extending out of the web no greater than one-half inch, the needles 26' are then withdrawn from the web and while the Web is still stationary.

When the needles 25' have been withdrawn from the web and just as penetration by the opposed array of needles 2% begins, the web makes another increment of movement in the direction of the arrow A. Since the needles 28' enter the web at the point where the respective aligned needles 26' projected through the web, some of the loop fibers previously brought through by the needles 26' are picked up near the surface of penetration by the needles 28 and are carried along horizontally with other surface fibers. The web It) then steps but penetration of the needles 28 continues through the web until the barbs closest to the needle points are adjacent to or extend no greater than one-half of an inch past the other surface of the web. Then the needles 28' are withdrawn while the web is stationary and once they are withdrawn the above-described operation is repeated. It will be understood that the needle patterns 22 and 24 reciprocate into and out of the web, the arrangement being such that there is alternate penetration of the web from opposite sides by the needle patterns 22 and 24 with two increments of advancement in each cycle.

Referring now to FIGURE 25, which schematically shows the path of the needles 26' and 28 through the web, the letter B represents the path of the reciprocating needles 2% through the web when the web is moved in step-by-step increments, the movement of the web being indicated just after the needles 2% begin their penetration. As shown in the lower portion of FIGURE 25, the

path B is somewhat horizontal as the needles 28 start into the web but once the web is stopped and the needles 2% continue their travel through the web, the path is vertical. Likewise, the needles 26' penetrating the top side of the web Iii have a path through the same as represented by the letter C'. Their path is similar to the path of the needles 28' in that adjacent the upper surface and when the needles 26' first enter the web, the fibers adjacent the surface are dragged in a substantially horizontal direction as the web is moving perpendicular to the vertical movement of the needles. Once the web is stopped and with the needles 26' continuing their downward movement, some of the fibers moved horizontally are then moved vertically as well as other fibers which are picked up as the needles descend through the web. FIGURE 25 which represents a pair of point-on-point needles 26 and 28' clearly illustrates that the point of penetration on surface of the web of one needle is at the point which the oppositely disposed aligned needle extended out of the This arrangement results in some of the surface and subsurface fibers of the web being oriented toward the opposite surface and then entangled with some of these surface fibers and oriented parallel to this surface and back toward the first-mentioned surface of the web.

The pattern 22' of needles 26 is substantially identical with the pattern described in connection with FIGURE 4, it being understood that the needle arrangement diiiers only in that the needles 26' are arranged to move in a path perpendicular to the fabric.

The needle punching apparatus 12' includes a frame structure 44' made from suitable vertical standards 46, side frame members 43 and cross members 50'. Mounted on the upper side frame members 48 on each side of the frame structure 44 are a pair of spaced parallel vertical plates 52' which are adapted to support therebetween the guide plates 32' and 34 respectively. In more detail, the plates 52 are provided with slots 54 extending vertically downwardly from their upper edge, the slots 54 being adapted to receive studs 56' of bracket members 58' which are fixedly secured to the upper surface of the upper plate 32'. The lower plate 34' is supported by L- shaped brackets 69' welded to the side plates 52 and to the bottom of the guide plate 34. As is now evident, the upper plate 32 may be adjusted relative the lower plate 34 by supporting the studs 56 at a desired height in the slots 54-.

Side plates 52' are provided with the horizontally extending slots 62' and 64. Slots 62' of side plates 52' are adapted to receive ends of a shaft 66' which supports one pulley 68 of an endless conveyor structure 70'. The portion of the shaft 66 which extends outwardly of the plate 52 shown in FIGURE 19 is provided with a drive sprocket 72.

Slots 64' in plates 52 are adapted to receive the ends of a shaft 74' which supports an outfeed roller 76. Carried outwardly of the plates 52 on the end of the shaft 7 is a drive sprocket 78' (FEGURE 19). The other end of the shaft 74 is coupled to a one-way clutch and brake assembly 8% (FIGURE 20). A drive chain 82' extending around the sprockets 72 and 78 and an idler sprocket 84' cause the pulley so to be rotated in step-by-step increments when the shaft 74 is rotated in step-by-step increments by the one-way clutch and brake assembly 38'.

Cooperating with the outfeed roller is is a Weighted roller 86 carried on the shaft 88 supported in diametrically opposed slots 99' provided in plates 52'. The shaft 88 is provided on its outer ends with weights 92 so that the roller 86' will bear against the upper surface of the non-woven fabric 14 as it is discharged from the machine.

Mounted on drive member of the one-way clutch Si? is a crank arm 94-. A connecting arm 96 (FIG- URE 19) connects the crank 9 with a disk or wheel 93 keyed to a shaft 1% rotatably supported in the bearing pillows 1G2. Shaft 1% carries a drive wheel 1G4 which is rotated by a belt 1% coupled to a source of power such as an electric motor 108. As will now be understood, continuous rotation of the shaft 1% by the motor 198 will cause the crank )4 to oscillate back and forth. Since the crank 94 is connected to the drive member of the one-way clutch and brake assembly 88', clockwise movement of the crank will cause rotation of the outfeed roller 1 6' as well as the infeed conveyor 75. During counterclockwise movement of the crank 94, the roller 75' and the conveyor 79' will be stationary and, consequently, there will be no feed of the web 1% through and out of the machine.

As previously stated, the upper needle pattern 22' includes a plurality of downwardly extending needles 26 whereas the lower needle pattern 2 includes a plurality of upwardly extending needles 28. The needles 25 and 28' are arranged to pass through aligned holes 110 provided the upper and lower web guide plates 32' and 3 t respectively. The needles 26 are secured in a needle board or holder 11?. fixedly secured to a reciprocating plate 114' by bolts, clamps or other suitable means. The reciprocating plate 114 is adjustably mounted on a pair of reciprocating rods 113 carred in vertical sleeves or slide bearings 12%) supported on the upper side frame members 8. The lower set of needles 2.8 are suitably supported in a needle board or holder 122' fixedly supported on a reciprocating plate 12 3. Plate 124 is adjustably supported on the reciprocating rods in spaced relationship beneath the upper needle board E12 and plate 114'. As shown in FIGURE 21, the rods 118 are threaded and by adjustment of nuts 126, the lower plate 124 and upper plate 114 can be adjusted vertically with respect to each other so that the distance between the points of the needles 25 and 28 respectively can be varied.

Each lower end of the reciprocating rods 118' is pivotally connected as indicated at Hill to connecting rods 132'. The other end of each of the connecting rods 132 is connected to cranks 134' mounted on the ends of a shaft 156' rotatably supported in the bearing pillow blocks 14%). A sprocket 142' carried on the shaft 136' is driven by a chain 146' also trained around a sprocket 148' carried on the drive shaft flit). As is now apparent by an inspection of FIGURES 19 and 20, rotation of the drive shaft by the motor 108 will cause rotation of the cranks 134 so that the connecting arms 132 reciprocate the rods 118' to simultaneously move both needle patterns 22 and 2 4' in a path normal to the path of travel of the web It) through the machine. The reciprocation of the needle patterns 22 and 24' is so timed with the intermittent feed of the web 10' that the needles of each of the patterns will penetrate the web when the web is moving. However, as soon as the needles of the particular pattern 22' or 24 enter the surface of the web, the advancement of the webs stops as the needles continue their movement through the web and the web remains stationary until the needles of the particular pattern are withdrawn. After the needles of one of the patterns are withdrawn from the surface of the web and as the needles of the pattern are beginning to penetrate the opposite surface, the web will begin its advancement. When the web it) again stops, needle penetration continues through the web.

Referring now to FlGURE 21, it will be noted that the first few rows of needles 26' and 23 or" upper and lower needle patterns 22 and 2 4 respectively pass through the curved inlet portions 36' and 38 of the guide plates 32. and 34'. Some of these needles do not pass cornpleteiy through the web as heretofore described but merely enter the web and compress the web in the tapering infeed portion '40" of throat 3-9. In other words, the needles in this forward portion are not entirely effective to cause interlacing and/or interlooping of the loosely matted fibers but they do compress the web to proper thickness and density for passage through the confined throat 3ft.

The contour of plates 32' and 34 is such that they conform to the web as it is compressed, i.e., they allow no up and down flapping motion of the web driving the needling process.

A flywheel 15% mounted on the shaft 136' provides sufficient inertia to the drive mechanism of the apparatus once the apparatus is started so that it reduces the power necessary to drive the same. Any suitable braking means may be used to compensate for inertia of the flywheel and assist in stopping the apparatus after the motor 1% is shut off.

The terms warpwise and fillingwise have been used in the specification to define direction relative to the needled fabric structure so that comparisons to a woven fabric having a warp and a filling can be made. In essence, *wiarpwise is used to mean a direction along the length whereas fillingwise is used to mean a dire"- tion across the width of the needled fabric structure.

While the objects and advantages of the needled fabric structure or" the present invention have been fully and effectively accomplished by the methods and apparatus described, it will be understood that other methods and apparatus might be used to make such fabric structures.

The terminology used in the specification is for the purpose of description and not limitation, the scope of the invention being defined in the claims.

What is claimed is:

1. A fabric structure characterized by having outer surfaces capable of uniform napping, and by having a high tensile and separation strength after napping comprising: a needle batt having fibers therein coherently oriented throughout the batt into a plurality of rows of fibers, the rows of fibers lying in parallel planes and each row extending lengthwise of the batt and being substantially contiguous with an adjacent row, each row comprising a continuous chain entanglement of fibers in its plane throughout the length of the same, the continuous chain entanglement of fibers in each row being formed .iccessively throughout the length of the row by some of the fibers in the row extending from one surface of the butt to the other surface and being entangled with some of the fibers from the other surface in the same row and then returned toward the one surface with the some of the fibers of the other surface, and then the some of the fibers from the other surface being entangled with other fibers in the one surface with some being returned toward the other surface with the same and so forth successively throughout the length of the row; and some of the fibers in each row between the surfaces being entangled with other fibers in the row and with fibers in adjacent rows.

2. The fabric structure of claim 1 wherein said plurality of rows of fibers in chain entanglement include at least twenty-five rows for each widthwise inch of fabric structure.

3. The fabric structure of claim 1 wherein adjacent substantially contiguous rows of fibers are staggered lengthwise of the fabric structure whereby fibers of one row extending from one surface toward the other are offset lengthwise with respect to similarly oriented fibers in the adjacent rows.

4. The fabric structure of claim 3 wherein said plurality of rows includes at least twenty-five rows per widthwise inch of the fabric structure.

5. A fabric structure characterized by having outer surfaces capable of uniform napping, and by having a high tensile and separation strength after napping comprising: a needle batt having fibers therein coherently oriented throughout the butt into a plurality of rows of fibers, the rows of fibers lying in parallel planes and each row extending lengthwise of the batt and being substantially contiguous with an adjacent row, each row comprising a continuous chain entanglement of fibers in its plane throughout the length of the same, the continuous chain entanglement of fibers in each row being formed successively throughout the length of the row by some of the fibers in the row extending from one surface of the batt toward the other surface at an acute angle to the one surface and being entangled with some of the fibers from the other surface in the same row and then returned toward the one surface with the some of the fibers of the other surface at an acute angle to the other surface, and then the some of the fibers from the other surface being entangled with other fibers in the one surface with some being returned toward the other surface with the same at an acute angle to the one surface and so forth successively throughout the length of the row; and 3 some of the fibers in each row between the surfaces being 16 entangled with other fibers in the row and with fibers in adjacent rows. 7

6. The fabric structure of claim 5 wherein said plurality of rows includes at least twenty-five rows per widthwise inch of the fabric structure.

7. The fabric structure of claim 5 wherein said plurality of rows includes in the order of twenty-five to seventy-five rows per width-wise inch of the fabric structure.

8. The fabric structure of claim 5 wherein adjacent rows are staggered length-wise with respect to each other whereby fibers of one row extending at an acute angle to surfaces of the fabric structure are offset lengthwise with respect to similarly oriented fibers of adjacent rows.

9. The fabric structure of claim 5 wherein the fibers extending at an acute angle to the surface of the fabric structure have an angle of at least 8 to a normal through the batt.

10. A fabric structure characterized by having outer surfaces capable of uniform napping and by having a high tensile and separation strength after napping comprising: a needle :batt having fibers therein coherently oriented throughout the batt into a plurality of rows of fibers, the rows of fibers lying in parallel planes and each row extending length-wise of the batt and being substantially contiguous with an adjacent row, each row comprising a continuous chain entanglement of fibers in its plane throughout the length of the same, the continuous chain entanglement of fibers in each row being formed successively throughout the length of the row by some of the fibers in the row extending from adjacent one surface of the batt in a direction substantially parallel to the one surface and the length of the batt and then extending through the batt to the other surface where they are entangled with other fibers from the other surface extending parallel to the other surface and to the length of the batt and then return toward the one surface with the fibers from the other surface, and then some of the latter fibers of the other surface being entangled with additional fibers of the one surface and extending parallel thereto and being returned with the same toward the other surface and so forth successively throughout the length of the row; and some of the fibers in each row between the surface being entangled with other fibers in the row and with fibers in adjacent rows.

11. The fabric structure of claim 10 wherein some of the fibers extending from one surface to the other are oriented substantially normal to the surfaces of the fabric structure.

12. The fabric structure of claim 10 wherein said plurality of rows includes at least twenty-five rows per widthwise inch of the fabric structure.

References Cited in the file of this patent UNITED STATES PATENTS 

1. A FABRIC STRUCTURE CHARACTERIZED BY HAVING OUTER SURFACES CAPABLE OF UNIFORM NAPPING, AND BY HAVING A HIGH TENSILE AND SEPARATION STRENGTH AFTER NAPPING COMPRISING: A NEEDLE BATT HAVING FIBERS THEREIN COHERENTLY ORIENTED THROUGHOUT THE BATT INTO A PLURALITY OF ROWS OF FIBERS, THE ROWS OF FIBERS LYING IN PARALLEL PLANES AND EACH ROW EXTENDING LENGTHWISE OF THE BATT AND BEING SUBSTANTIALLY CONTIGUOUS WITH AN ADJACENT ROW, EACH ROW COMPRISING A CONTINUOUS CHAIN ENTANGLEMENT OF FIBERS IN ITS PLANE THROUGHOUT THE LENGTH OF THE SAME, THE CONTINUOUS CHAIN ENTANGLEMENT OF FIBERS IN EACH ROW BEING FORMED SUCCESSIVELY THROUGHOUT THE LENGTH OF THE ROW BY SOME OF THE FIBERS IN THE ROW EXTENDING FROM ONE SURFACE OF THE BATT TO THE OTHER SURFACE AND BEING ENTANGLED WITH SOME OF THE FIBERS FROM THE OTHER SURFACE IN THE SAME ROW AND THEN RETURNED TOWARD THE ONE SURFACE WITH THE SOME OF THE FIBERS OF THE OTHER SURFACE, AND THEN THE SOME OF THE FIBERS FROM THE OTHER SURFACE BEING ENTANGLED WITH OTHER FIBERS IN THE ONE SURFACE WITH SOME BEING RETURNED TOWARD THE OTHER SURFACE WITH THE SAME AND SO FORTH SUCCESSIVELY THROUGHOUT THE LENGTH OF THE ROW; AND SOME OF THE FIBERS IN EACH ROW BETWEEN THE SURFACES BEING ENTANGLED WITH OTHER FIBERS IN THE ROW AND WITH FIBERS IN ADJACENT ROWS. 